Structural isothermal construction sip panel and methods

ABSTRACT

A structural isothermal construction SIP panel comprising a board made of insulating material with two cement-based boards attached to said board made of insulating material per each one of its faces. The insulating board has in each of its sides a “C” type galvanized metal profile, that is embedded in the insulating board and the cement-based boards are attached to the insulating board and are placed overlapped opposite to each other with respect to their longitudinal axis, the overlapped bonding of the cement-based boards with the insulating board creates a protruding area which has a width equal to the width of the galvanized metal profile the bonding between two panels is made using screws. Two manufacturing methods and a bonding method are also provided.

SCOPE OF THE INVENTION

The field of application of the present invention is that of construction panels, specifically SIP (Structural Insulated Panels) construction panels or Structural Isothermal Panels.

DESCRIPTION OF THE PRIOR ART

SIP construction panels are composite and high-performance panels used in floors, walls and ceilings for light residential and commercial buildings. These panels are manufactured in a factory and shipped to the construction site, where they can be quickly assembled to form an airtight and highly energy-efficient building envelope.

SIP panels are a simple composite sandwich panel. ASTM (American Society for Testing Materials) International defines these panels as “a three-layer construction formed by bonding a thin layer (face) on each side of a thick layer (core).” The term “composite” refers to any material in which two or more different materials are combined together, and yet remain uniquely identifiable in the mixture.

Generally, SIP panels are manufactured by sandwiching a core of rigid plastic insulating foam between two structural skins, although many different variations are included in the definition (based on the faces and the core materials). SIP panels are made with a variety of skin structural materials, including oriented strand board (OSB), treated plywood, metal and cement fiberboards (cement-based). However, any material which can be attached may be used as a coating. The basic materials of the core are typically expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane, but other rigid insulators can also be used. The faces and the cores are bonded by structural adhesives. These variables allow the panels can be optimized to the specific needs of a project. SIP panels are usually available in thicknesses ranging from 11.43 cm to 31.11 cm (4½″ to 12¼″).

The walls are normally between 10.16 cm and 15.24 cm (4″ to 6″), and the ceiling panels are generally thicker, often up 30.45 cm (12″), depending on climatic conditions. SIP panels with cement coatings tend to reduce to 121.92 cm by 243.84 (4 feet by 8 feet). SIP panels can be as large as 9 feet by 28 feet. OSB coatings also have custom sizes and many manufacturers offer curved SIP panels for curved ceiling applications. This design flexibility, as well as different core combinations and coating materials, allow unique performance properties for each project. The flexibility of SIP panels, their resistance and energy efficiency make them an important construction material for high performance buildings.

SUMMARY OF THE INVENTION

The invention proposes a SIP panel based on cement boards, an insulating board and galvanized steel profiles, which allows an easy installation and which achieves an easy bonding between one board and the other in which connectors can be inserted possibly due to the shape of components in the bonding areas. Also, the use of galvanized steel profiles allows the panel to be structural and self-supporting and need only screws to bond a panel to the other.

In this way, it is possible to obtain a lightweight panel, with a desirable finish and bonding for assembly with another similar panel. The construction sites using these panels may reduce labor time, up to one third, compared to traditional constructions.

The insulating materials most commonly used for this type of panel preferably include expanded polystyrene (EPS), also using extruded polystyrene (XPS), rigid insulating polyurethane or any other rigid insulator. The materials most commonly used for cement-based boards include preferably silicate reinforced with fiberglass mesh and adhesive, also using plaster or concrete consisting of small particle size sands, cement, additives, in addition, materials for improving flexibility can also be incorporated, such as metals, irons, glass fibers, vegetable or mineral fibers, polypropylene, nylon, and others. The bonding of cement-based boards with the insulating board is preferably made with polyurethane or cement-based adhesive, being able to use any other adhesive that permits such bonding.

These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIG. 1 shows a cross section of a panel of the invention that has been glued with adhesive and screws;

FIG. 2 shows a cross section of a panel of the invention using a metal box and polystyrene blocks with a release agent;

FIG. 3 shows an isometric view of the panel of the invention;

FIG. 4 shows how to embed the insulating board into the galvanized metal profiles;

FIGS. 5 a, b, c, d, e and f show a sequence of a method of manufacturing the panel according to an AA view of the metal box;

FIG. 6 shows the metal box and the polystyrene blocks with a release agent; and,

FIG. 7 shows the bonding of two panels and a detail in the bonding area.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.

It should be further understood that the title of this section of this specification, namely, “Detailed Description of the Invention,” relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.

The proposed invention refers to an SIP panel structured with two cement-based boards (2) and in its center an insulating board (1), to each of the side edges of the insulating board (1) a galvanized metal “C” profile is fixed (3) along its length. Each of the two cement-based boards (2) is attached to the insulating board (3) in its entire contact surface. The galvanized metal profile (2) is fixed to the edges of the insulating board (1) surrounding its edge, leaving a portion of the insulating board (1) inside the galvanized metal profile (3). Each of the cement-based boards (2) is extended beyond the edge of the galvanized metal profile (3), creating a protruding area (A), these protruding areas (A) are arranged in opposite locations in each of the cement-based boards with reference to a longitudinal axis along the panel, and have a width equal to the width of the wing of the galvanized metal profile (B).

The panel comprises two “C” type galvanized metal profiles (3) made of galvanized structural iron with about 0.85 mm (0.033″) thickness, variable height and width, depending on the thickness desired for the panel. The insulating board (1) also has a variable thickness, while the cement-based board (2) is preferably made of silicate reinforced with glass fiber mesh and adhesive.

With regard to the manufacturing of the panel of the invention, this can be achieved by two methods, achieving in the second method a bonding where the adhesive capacity of fresh concrete with polystyrene and metal is used, which avoids using screws and adhesive as in the case of Method 1. These two methods are detailed below:

Method 1

a) Provide an insulating board (1).

b) Provide two cement-based boards (2), one of which may be made of plasterboard.

c) Provide two galvanized metal profiles, “C” type (3).

d) Provide adhesive.

e) Embed the insulating board (1) entirely between the two galvanized metal profiles (3) (FIG. 4).

f) Attach to each side of the insulating board (1) with the galvanized metal profiles (3) already embedded one of the two cement-based boards by placing them overlapped opposite to each other.

g) Attach the cement-based boards (2) to the insulating board (1) such that the protruding area (A) resulting from the overlapping equals the width of the wing of the galvanized metal profile (B).

h) Attach the cement-based boards (2) to the insulating board (1) such that the end of the cement-based board (2) which is not a protruding area (A) is stuck on the insulating board from where the width of the wing of the galvanized metal profile (B) ends.

i) Use screws (10) to ensure a better bonding of the cement-based board with the assembly formed by the insulating board (1) and the galvanized metal profiles (3).

Method 2

a) Provide an insulating board (1).

b) Provide two galvanized metal profiles, “C” type (3).

c) Embed the insulating board (1) entirely between the two galvanized metal profiles (3).

d) Provide a metal box (11) (FIG. 5 a).

e) Provide polystyrene blocks with a release agent (12,15).

f) Provide fresh cement.

g) Place a first polystyrene block with a release agent (12) on one side of the metal box (11), (FIG. 5 b).

h) Pour and spread the release agent on the floor of the metal box

i) Pour fresh cement on the floor of the metal box (11) to a thickness determined in the space between the first polystyrene block with a release agent (12) and the edge of the metal box (11), immersing in said fresh cement already poured a mesh, preferably made of glass fiber, to form a first cement-based board (13) (FIG. 5 c).

j) Place on the first cement-based board (13), still fresh and attached to the first polystyrene block with a release agent (12), the set formed by the two galvanized metal profiles (3) and the insulating board (1) of step d). (FIG. 5 d)

k) Place a second polystyrene block with a release agent (15) in the space between the metal profile (3) and the edge of the metal box (11). (FIG. 5 e)

l) Pour fresh cement into the space between the second polystyrene block with a release agent (15) and the edge of the metal box (11), immersing in said fresh cement already poured a mesh, preferably made of glass fiber, to form a second cement-based board (14) (FIG. 5 f).

m) Once it is dried, remove the panel from the box.

Further described below is a method for bonding two panels as those of the invention:

a) Provide a first and a second panel.

b) Provide screws (16).

c) Provide connectors (if applicable).

d) Place the connectors between the bonding areas of the two panels (if applicable).

e) Place the overlapping of the protruding area (A) of the first panel against the wing of the galvanized metal profile (3) of the second panel along its length.

f) Use screws (16) to secure the overlapping of the protruding area of the first panel with the wing of the galvanized metal profile (3) of the second panel along its length.

g) In case of adding more panels, start again from item a) to g).

The type of screw used to bond the cement-based board to the metal profile and the type used to bond two panels is preferably anti-alkali self-tapping.

All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure.

In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. 

What is claimed is:
 1. A structural isothermal construction SIP panel comprising an insulating board made of insulating material with two cement-based boards attached to said board made of insulating material per each one of its faces, wherein: the insulating board has in each of its sides a “C” type galvanized metal profile, that is embedded in the insulating board; the cement-based boards are attached to the insulating board and are placed overlapped opposite to each other with respect to their longitudinal axis; the overlapped bonding of the cement-based boards with the insulating board creates a protruding area which has a width equal to the width of the galvanized metal profile; and bonding between two panels is made using screws.
 2. A structural isothermal construction SIP panel according to claim 1, wherein the insulating board is made of expanded polystyrene.
 3. A structural isothermal construction SIP panel according to claim 1, wherein the insulating board is made of extruded polystyrene, rigid insulating polystyrene or other rigid insulating material.
 4. A structural isothermal construction SIP panel according to claim 1, wherein the cement-based board material is silicate reinforced with fiberglass mesh and adhesive.
 5. A structural isothermal construction SIP panel according to claim 1, wherein the cement-based board is bonded to the insulating board by using polyurethane or cement-based adhesive.
 6. A structural isothermal construction SIP panel according to claim 1, wherein the cement-based board is bonded with the insulating board by using the bonding capacity of fresh cement.
 7. A structural isothermal construction SIP panel according to claim 1, wherein the materials of the cement-based board include stucco or concrete comprising small particle size sands, cement and/or additives, and/or metals, irons, glass fibers, vegetable or mineral fibers, polypropylene or nylon.
 8. A structural isothermal construction SIP panel according to claim 1, wherein the “C” type metal profiles are made of structural galvanized iron of about 0.85 mm (0.033″) thickness and variable height and width depending on the dimensions of the panel.
 9. A structural isothermal construction SIP panel according to claim 1, wherein the type of screw used to attach the cement-based board to the metal profile and the type of screw used to bond two panels is anti-alkali self-tapping.
 10. A structural isothermal construction SIP panel according to claim 1, wherein said panel further comprises an inner face made of a plasterboard.
 11. A structural isothermal construction SIP panel according to claim 1, wherein all profiles are pre-embedded inside.
 12. A method for manufacturing a structural isothermal construction SIP panel, the method comprising the steps of: a) providing an insulating board; b) providing two cement-based boards; c) providing two “C” type galvanized metal profiles; d) providing adhesive; e) embedding the insulating board entirely between the two galvanized metal profiles; f) attaching to each side of the insulating board with the galvanized metal profiles already embedded one of the two cement-based boards placing them overlapped opposite to each other; g) attaching the cement-based boards to the insulating board such that the protruding area resulting from the overlapping equals the width of the wing of the galvanized metal profile; h) adhering the cement-based boards to the insulating board such that the end of the cement-based board which is not a protruding area is stuck on the insulating board from where the width of the wing of the galvanized metal profile ends; and i) screwing a fastener to bond the cement-based board with the assembly formed by the insulating board and the galvanized metal profiles.
 13. A method for manufacturing a structural isothermal construction SIP panel, the method comprising the steps of: a) providing an insulating board; b) providing two “C” type galvanized metal profiles; c) embedding the insulating board entirely between the two galvanized metal profiles; d) providing a metal box; e) providing polystyrene blocks with a release agent; f) providing fresh cement; g) placing a first polystyrene block with a release agent on one side of the metal box; h) pouring and spreading the release agent on the floor of the metal box; i) pouring fresh concrete on the floor of the metal box to a thickness determined in the space between the first polystyrene block with a release agent and the edge of the metal box; j) immersing in said fresh cement already poured a mesh, preferably made of glass fiber, to form a first cement-based board; k) placing on the first cement-based board, still fresh and attached to the first polystyrene block with a release agent, the set formed by the two galvanized metal profiles and the insulating board of step c); l) placing a second polystyrene block with a release agent in the space between the metal profile and the edge of the metal box; m) pouring fresh cement into the space between the second polystyrene block with a release agent and the edge of the metal box; n) immersing in said fresh cement already poured a mesh, to form a second cement-based board; and o) removing the panel from the box once it is dried.
 14. A bonding method for structural isothermal construction SIP panels, the method comprising the steps of: a) providing a first panel and a second panel; b) providing screws; c) providing connectors; d) placing the connectors between the bonding areas of the two panels; e) placing the overlapping of the protruding area of the first panel against the wing of the galvanized metal profile of the second panel along its length; and f) screwing fasteners to secure the overlapping of the protruding area of the first panel with the wing of the galvanized metal profile of the second panel along its length. 